mundoclima Aerotherm V17 Series User manual

BIBLOC UNIT - AEROTHERM V17
Service Manual
English
www.mundoclima.com
SO30160 to SO30172
Thank you very much for purchasing our product.
Before using your unit, please read this manual carefully
and keep it for future reference.
2nd Version

201703 1
CONTENTS
CONTENTS
Part 1 General Information............................................................................ 3
Part 2 Component Layout and Refrigerant Circuits ..................................... 5
Part 3 Control ............................................................................................... 13
Part 4 Diagnosis and Troubleshooting......................................................... 27
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Part 1 - General Information
Part 1
General Information
1 Unit Capacities ........................................................................................... 4
2 External Appearance .................................................................................. 5
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1 Unit Capacities
1.1 Outdoor Unit Capacities
Table 1-1.1: Capacity range
C
apacity
4kW
6kW
8kW
10kW
12kW
14kW
16kW
Capacity
12kW
14kW
16kW
1.2 Hydronic Box Capacities
Table 1-2.1: Capacity range
Capacity
8kW
16kW
16kW
Model
Compatible OU model
BIBLOC
V17 (3Ph)
BIBLOC
V17 (1Ph) SO30160 SO30161 SO30162 SO30163 SO30164 SO30165
SO30167 SO30168 SO30169
SO30166
SO30170 SO30171 SO30172
SO30167 to SO30169
SO30163 to SO30166
SO30160 to SO30161
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Part 1 - General Information
2 External Appearance
2.1 Outdoor Unit Appearance
Table 1-2.1: Outdoor unit appearance
4/6kW
8kW
10/12/14/16kW
2.2 Hydronic Box Appearance
Table 1-2.1: Hydronic box appearance
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Part 2 - Component Layout and Refrigerant Circuits
Part 2
Component Layout and
Refrigerant Circuits
1Layout of Functional Components ......................................................... 6
2Piping Diagrams .................................................................................... 9
3Refrigerant Flow Diagrams .................................................................. 12
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1 Layout of Functional Components
1.1 Outdoor Unit Layout
Figure 2-1.1:
top view
4-way valve Electronic expansion
valve
Gas side stop valve
Liquid side stop valve
Figure 2-1.2:
front view
DC inverter compressor
Accumulator
Air side heat exchanger Fan motor
Separator
Pressure sensor
High pressure switch
Low pressure switch
Electric control box
Models 4 to 8kW
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Part 2 - Component Layout and Refrigerant Circuits
Figure 2-1.4:
top view
4-way valve
Gas side stop valve
Liquid side stop valve
Figure 2-1.5:
front view
Air side heat exchanger
Upper fan motor Lower fan motor
Electronic expansion valve
DC inverter compressorAccumulator
Electric control box
Pressure sensor
High pressure switch
Low pressure switch
Separator
Models 10 to 16kW
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1.2 Hydronic Box Layout
Figure 2-1.6:
oblique view
Electric control box
Air purge valve
Expansion vessel
Water pump
Water side heat exchanger
Manometer
Water flow switch
Safety valve
Backup electric heater
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Part 2 - Component Layout and Refrigerant Circuits
2 Piping Diagrams
2.1 Outdoor Unit Piping
Figure 2-2.1:
piping diagram
Legend
1
Compressor
7
Electronic expansion valve
2.1
Discharge pipe temperature sensor
8
Accumulator
2.2
Outdoor ambient temperature sensor
9
Stop valve (liquid side)
2.3
Air side heat exchanger refrigerant outlet temperature sensor
10
Stop valve (gas side)
2.4
Suction pipe temperature sensor
11
Pressure sensor
3
4
-way valve
12
Separator
4
Air side heat exchanger
13.1
Low pressure switch
5
Distributor
13.2
High pressure switch
6
Filter
Key components:
1. Accumulator:
Stores liquid refrigerant and oil to protect compressor from liquid hammering.
2. Electronic expansion valve (EXV):
Controls refrigerant flow and reduces refrigerant pressure.
3. Four-way valve:
Controls refrigerant flow direction. Closed in cooling mode and open in heating mode. When closed, the air side heat
exchanger functions as a condenser and water side heat exchanger functions as an evaporator; when open, the air
side heat exchanger functions as an evaporator and water side heat exchanger function as a condenser.
4. High and low pressure switches:
Regulate refrigerant system pressure. When refrigerant system pressure rises above the upper limit or falls below the
lower limit, the high or low pressure switches turn off, stopping the compressor.
5. Separator:
Separates liquid refrigerant from gas refrigerant to protect compressor from liquid hammering.
Models 4 to 8kW
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Figure 2-2.2:
piping diagram
Legend
1
Compressor
8
Accumulator
2.1
Discharge pipe temperature sensor
9
Stop valve (liquid side)
2.2
Outdoor ambient temperature sensor
10
Stop valve (gas side)
2.3
Air side heat exchanger refrigerant outlet temperature
sensor
11
Pressure sensor
2.4
Suction
pipe temperature sensor
12
Separator
3
4-way valve
13.1
Low pressure switch
4
Air side heat exchanger
13.2
High pressure switch
5
Distributor
14
Solenoid valve
6
Filter
15
Capillary
7
Electronic expansion valve
Key components:
6. Accumulator:
Stores liquid refrigerant and oil to protect compressor from liquid hammering.
7. Electronic expansion valve (EXV):
Controls refrigerant flow and reduces refrigerant pressure.
8. Four-way valve:
Controls refrigerant flow direction. Closed in cooling mode and open in heating mode. When closed, the air side heat
exchanger functions as a condenser and water side heat exchanger functions as an evaporator; when open, the air
side heat exchanger functions as an evaporator and water side heat exchanger function as a condenser.
9. High and low pressure switches:
Regulate refrigerant system pressure. When refrigerant system pressure rises above the upper limit or falls below the
lower limit, the high or low pressure switches turn off, stopping the compressor.
10. Separator:
Separates liquid refrigerant from gas refrigerant to protect compressor from liquid hammering.
11. Solenoid valve:
Protects the compressor. If compressor discharge temperature rises above 100°C, 6.Solenoid valve opens and sprays a
small amount of liquid refrigerant to cool the compressor. Solenoid valve closes again once the discharge temperature
has fallen below 90°C.
Models 10 to 16kW
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Part 2 - Component Layout and Refrigerant Circuits
2.2 Hydronic box Piping
Figure 2-2.1:
piping diagram
Legend
1
Air purge valve
11 Water outlet
2
Backup electric heater
12 Water inlet
3
Expansion vessel
13.1
Water side heat exchanger refrigerant outlet (gas pipe) temperature
sensor
4
Refrigerant liquid
side
13.2
Water side heat exchanger refrigerant inlet (liquid pipe) temperature
sensor
5
Refrigerant gas side
13.3
Water side heat exchanger water outlet temperature sensor
6
Water side heat exchanger
13.4
Water side heat exchanger water inlet temperature sensor
7
Water flow switch
13.5
Backup electric heater water outlet temperature sensor
8
Water pump
14.1
Anti-frozen electric heater for water side heat exchanger
9
Manometer
14.2
Anti-frozen electric heater for water inlet pipe
10
Safety valve
Key components:
1. Air purge valve:
Automatically removes air from the water circuit.
2. Safety valve:
Prevents excessive water pressure by opening at 43.5 psi (3 bar) and discharging water from the water circuit.
3. Expansion vessel:
Balances water system pressure. (Expansion vessel volume: 3L.)
4. Water flow switch:
Detects water flow rate to protect compressor and water pump in the event of insufficient water flow.
5. Backup electric heater:
Provides additional heating capacity when the heating capacity of the heat pump is insufficient due to very low
outdoor temperature. Also protects the external water piping from freezing.
6. Manometer:
Provides water circuit pressure readout.
7. Water pump:
Circulates water in the water circuit.
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3 Refrigerant Flow Diagrams
Heating and domestic hot water operation
Figure 2-3.1: Refrigerant flow during heating or domestic hot water operation
Cooling and defrosting operation
Figure 2-3.2: Refrigerant flow during cooling and defrosting operations
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Part 3 - Control
Part 3
Control
1 Stop Operation ........................................................................................ 14
2 Standby Control ....................................................................................... 14
3 Startup Control ........................................................................................ 15
4 Normal Operation Control ....................................................................... 17
5 Protection Control ................................................................................... 19
6 Special Control......................................................................................... 22
7 Role of Temperature Sensors in Control Functions ................................... 24
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1 Stop Operation
The stop operation occurs for one of the following reasons:
1. Abnormal shutdown: in order to protect the compressors, if an abnormal state occurs the system makes a 'stop with
thermo off’ operation and an error code is displayed on the outdoor unit PCB digital displays and on the user
interface.
2. The system stops when the set temperature has been reached.
2 Standby Control
2.1 Crankcase Heater Control
The crankcase heater is used to prevent refrigerant from mixing with compressor oil when the compressors are stopped.
The crankcase heater is controlled according to outdoor ambient temperature and the compressor on/off state. When the
outdoor ambient temperature is above 8°C or the compressor is running, the crankcase heater is off; when the outdoor
ambient temperature is at or below 8°C and either the compressor has been stopped for more than 3 hours or the unit has
just been powered-on (either manually or when the power has returned following a power outage), the crankcase heater
turns on.
2.2 Water Pump Control
When the outdoor unit is in standby, the internal and external circulator pumps run continuously.
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Part 3 - Control
3 Startup Control
3.1 Compressor Startup Delay Control
In initial startup control and in restart control (except in oil return operation and defrosting operation), compressor startup
is delayed such that a minimum of the set re-start delay time has elapsed since the compressor stopped, in order to
prevent frequent compressor on/off and to equalize the pressure within the refrigerant system. The compressor re-start
delays for cooling and heating modes are set on the user interface. Refer to the M-Thermal Split Engineering Data Book
Part 3, 8.5 “COOL MODE SETTING Menu” and Part 3, 8.6 “HEAT MODE SETTING Menu”.
3.2 Compressor Startup Program
In initial startup control and in re-start control, compressor startup is controlled according to outdoor ambient
temperature. Compressor startup follows one of two startup programs until the target rotation speed is reached. Refer to
Figures 3-4.1, 3-4.2 and 3-4.3.
Figure 3-4.1: Compressor startup program1,2 when ambient temperature is above 4°C
38rps
Target rotation speed
Compressor rotation
speed (rps)
Time (s)

32rps 42rps 56rps 66rps 86rps
40s 60s 40s 40s 40s 40s
Notes:
1. Once the first, 40-second stage of the program is complete, the program proceeds to the subsequent
stages in a
step-by-step fashion and exits when the target rotation speed has been reached.
2. This program is used on all M-Thermal Split models: 4kW to 16kW, single phase and three phase.
Figure 3-4.2:
compressor startup program1when ambient temperature is at or below 4°C
Target rotation speed
Compressor rotation
speed (rps)
40s
38rps
90s
32rps
60s
42rps
40s
56rps
40s
66rps 40s
82rps
Time (s)
0
90s
36rps
Notes:
1. Once the first, 40-second stage of the program is complete, the program proceeds to the subsequent
stages in a
step-by-step fashion and exits when the target rotation speed has been reached.
Models 4 to 8kW
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Figure 3-4.3:
compressor startup program1when
ambient
temperature is at or below 4°C
38rps

Target rotation speed
Compressor rotation
speed (rps)
Time (s)
24rps 33rps 42rps
56rps 66rps
82rps
40s 90s 90s 60s 40s 40s
40s
Notes:
1. Once the first, 40-
second stage of the program is complete, the program proceeds to the
subsequent
stages in a
step-by-step fashion and exits when the target rotation speed has been reached.
3.3 Startup Control for Heating and Domestic Hot Water Operation
Table 3-4.1: Component control during startup in heating and domestic hot water modes
Component Wiring diagram
label 4-8kW 10-16kW
Control functions and states
I
nverter compressor COMP ƽƽ
C
ompressor startup program selected according
to
ambient
temperature
1
DC fan motor / Upper DC fan motor
FAN1 / FAN_UP ƽƽ
Fan
run at maximum speed2
Lower DC fan motor
FAN_DOWN ƽ
E
lectronic expansion valve EXV ƽƽ
Position (steps) from 0 (fully closed) to 480 (fully
open),
controlled according to
outdoor ambient
temperature, discharge temperature and
suction
superheat
Four-way valve
ST
ƽƽ
On
Notes:
1. Refer to Figure
3
-4.1, Figure 3-4.2 and Figure 3-4.3 in Part 3, 4.2 “Compressor Startup Program”.
2. Refer to
Table 3
-5.3 in Part 3, 5.6 “Outdoor Fan Control”.
3.4 Startup Control for Cooling Operation
Table 3-4.2: Component control during startup in cooling mode
Component
Wiring diagram
l
abel
4-8kW 10-16kW Control functions and states
I
nverter compressor COMP ƽƽ
Compressor startup program selected
according
to
ambient
temperature
1
DC fan motor / Upper DC fan motor
FAN1 / FAN_UP
ƽƽ
Fan
run at maximum speed2
Lower DC fan motor
FAN_DOWN
ƽ
E
lectronic expansion valve EXV ƽƽ
Position (steps) from 0 (fully
closed) to 480 (fully
open), controlled according to
outdoor ambient
temperature, discharge temperature and
suction
superheat
Four-way valve
ST
ƽƽ
Off
Notes:
1. Refer to Figure
3
-4.1, Figure 3-4.2 and Figure 3-4.3 in Part 3, 4.2 “Compressor Startup Program”.
2. Refer to Table 3-5.3
in Part 3, 5.6 “Outdoor Fan Control”.
Models 10 to 16kW
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Part 3 - Control
4 Normal Operation Control
4.1 Component Control during Normal Operation
Table 3-5.1: Component control during heating and domestic hot water operations
Component
Wiring diagram
label 4-8kW
10-16kW
Control functions and states
I
nverter compressor COMP ƽƽ
Controlled
according to load requirement
from
hydronic system
DC fan motor / Upper DC fan motor
FAN1 / FAN_UP
ƽƽ
Controlled
according to
outdoor heat exchanger
pipe temperature
Lower DC fan motor
FAN_DOWN
ƽ
E
lectronic expansion valve EXV ƽƽ
Position (steps) from 0 (fully closed) to 480 (fully
open)
, controlled according to
discharge
temperature
, suction superheat and compressor
speed
F
our-way valve ST ƽƽ
O
n
Table 3-5.2: Component control during cooling operation
Component Wiring diagram
label 4-8kW 10-16kW
Control functions and states
I
nverter compressor COMP ƽ
ƽ
Controlled
according to load requirement
from
hydronic system
DC fan motor / Upper DC fan motor
FAN1 / FAN_UP
ƽƽ
Controlled according to outdoor heat exchanger pipe
temperature
Lower DC fan motor
FAN_DOWN
ƽ
E
lectronic expansion valve EXV ƽƽ
Position (steps) from 0 (fully closed) to 480 (fully
open)
, controlled
according to
discharge
temperature
, suction superheat
and compressor
speed
F
our-way valve ST ƽƽ
O
ff
4.2 Compressor Output Control
The compressor rotation speed is controlled according to the load requirement. Before compressor startup, the
M-Thermal Split outdoor unit determines the compressor target speed according to outdoor ambient temperature, leaving
water set temperature and actual leaving water temperature and then runs the appropriate compressor startup program.
Refer to Part 3, 4.2 “Compressor Startup Program”. Once the startup program is complete, the compressor runs at the
target rotation speed.
During operation the compressor speed is controlled according to the rate of change in water temperature, the refrigerant
system pressure and the refrigerant temperature.
4.3 Compressor Step Control
The running speed of four-pole compressors (used on 5-7kW models) in rotations per second (rps) is half the frequency (in
Hz) of the electrical input to the compressor motor. The running speed of six-pole compressors (used on all other models)
in rotations per second (rps) is one third of the frequency (in Hz) of the electrical input to the compressor motor. The
frequency of the electrical input to the compressor motors can be altered at a rate of 1Hz per second.
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4.4 Four way Valve Control
The four-way valve is used to change the direction of refrigerant flow through the water side heat exchanger in order to
switch between cooling and heating/DHW operations. Refer to Figures 2-3.1 and 2-3.2 in Part 2, 3 “Refrigerant Flow
Diagrams”.
During heating and DHW operations, the four-way valve is on; during cooling and defrosting operations, the four-way
valve is off.
4.5 Electronic Expansion Valve Control
The position of the electronic expansion valve (EXV) is controlled in steps from 0 (fully closed) to 480 (fully open).
At power-on:
yThe EXV first closes fully, then moves to the standby position (304 (steps)). After 30 seconds the EXV moves to an
initial running position, which is determined according to operating mode and outdoor ambient temperature.
After a further 150 seconds, the EXV is controlled according to suction superheat and discharge temperature.
Once a further 6 minutes have elapsed, the EXV is then controlled according to suction superheat, discharge
temperature and compressor speed.
When the outdoor unit is in standby:
yThe EXV is at position 304 (steps).
When the outdoor unit stops:
yThe EXV first closes fully, then moves to the standby position (304 (steps)).
4.6 Outdoor Fan Control
The speed of the outdoor unit fan(s) is adjusted in steps, as shown in Table 3-5.3.
Table 3-5.3: Outdoor fan speed steps
Fan speed index
Fan speed (rpm)
4kW 6kW 8kW
10-16kW (1Ph) 12-16kW (3Ph)
Upper fan1
Lower fan2
Upper fan
1
Lower fan
2
0 0 0 0 0 0 0 0
1 300 300 300 300 - 300 -
2 340 340 340 330 300 330 300
3 400 400 400 400 380 400 380
4 450 450 450 460 440 460 440
5 520 520 520 520 500 520 500
6
600
600 600 630 610 630 610
7 680 680 680 780 760 780 760
8 730 730 730 - - - -
9 800 800 800 - - - -
Notes:
1. The upper fan is labelled FAN_UP in the wiring diagram. Refer to the M-Thermal Split
Engineering Data Book
Part 2, 4
“
Wiring diagram”.
2. The lower fan is labelled FAN_DOWN in the wiring diagram. Refer to the M-Thermal Split
Engineering Data Book
Part 2, 4 “Wiring diagram”.
MUNDOCLIMA AEROTHERM V17 - BIBLOC